Fastening System for Panels and Trim

ABSTRACT

A fastening system for panels and trim having a fastening element including a reveal edge and a serpentine edge. A projection and a recess is disposed adjacent to each other on the same serpentine edge. The fastening element guides and connects adjacent panel faces into a flush horizontal alignment with each other. Panels with the fastening element on each side may be combined together in a multiple course structure. The fastening element accommodates dimensional changes in adjacent wood panels from moisture and temperature fluctuations by allowing for expansion both with the elimination of the gap in the serpentine edge expansion area and with the compression of the expansion relief aperture adjacent to the expansion bulge in the recess of the adjacent panel. An expansion relief aperture on the projection of a fastening element can receive a trim fastener for applying perimeter trim with a hidden fastener onto many structurally different panel designs.

BACKGROUND

This invention relates to paneling, specifically to an improved wood panel attachment and alignment system for interrelating adjacent wood panels.

A problem addressed by this invention arises from attaching and aligning paneling. Unresolved problems with some currently known solutions call for creating new ways of mounting panels to a wall surface and to trim the panel edges. A new system is needed for working with different panel versions that also accommodates different panel sizes and termination conditions. The perimeter of the panels needs a new trim element to protect the sometimes vulnerable edges of panels and to visually frame them. Panels could be expected to cover some wall surfaces and structures that would span multiple panels in multiple courses. Another consideration early in the process was the desire to avoid visible fasteners when attaching the panels to the wall surface.

To illustrate what may be involved, to obtain a flush fit of panel “A” to panel “B” with a conventional shoulder screw fully engaged in a clip, an installer needs to locate a shoulder screw from edge of “B” a distance equal to location of rear clip mounting screw from edge of “A” less a dimension X, where X varies with the clip type. One also may need to consult the specifications for his particular clip. For example, an installer with a 32 mm system boring, would need to drill shoulder screw holes 0.428″ (11 mm) closer to the edge than the rear clip-mounting hole.

In addition to those problems presented when hanging wood panels, there is also a dimensional change problem. Wood is a hygroscopic material that in high humidity picks up moisture and swells while in low humidity releases moisture and shrinks. Uncontrolled relative humidity below 20% or above 80% is likely to cause problems. While a user can clearly see the damaged wood paneling from subsequent dimensional change in wood, the responsibility for preventing and correcting the problem is not clear. The manufacturer of the wood paneling may deny responsibility pointing to the inherent natural property of wood to change dimensions. Other times it can be unclear whether or not the cause and responsibility for dimensional change problems in wood products was the result of improper design and whether it is the responsibility of the designer or architect or specifier. Also, the question of cause and responsibility for dimensional change problems in wood products resulting from improper relative humidity exposure during site storage and installation may not end with the general contractor. Responsibility for dimensional change problems in wood products resulting from humidity extremes after occupancy may not only be with engineering and maintenance. AWI/AWMAC 8th edition quality standards page 553 (2003). What is needed is to further address the subsequent dimensional change in wood panels.

A variety panel hanging systems have been known in the art for quite some time. For example, a panel hanging cleat system involves driving a an adequate length fastener such as a two and half-inch number ten sheet-metal screws through 1) the finished wall panel, 2) locking hanging cleats for the paneling, 3) to the wall or studs, and 4) an additional member behind the wall.

Another example is an interlocking extruded aluminum wall cleat system. Fasteners connect the wall panel to the cleat, to the wall, and then into a back member. The cleats are typically constructed of extruded aluminum. Blocking is typically installed by others. Shims are installed behind wall-mounted members. An instrument is required for proper field layout to level and to plumb panels. The number and placement of cleats must be determined in consultation with an installation team. AWI/AWMAC 8th edition quality standards page 529 (2003).

These and various other options for attaching the panels to the wall were considered but were eventually found wanting. Screwing or nailing through the face of the panel were options that were rejected immediately. Using an extruded aluminum “Z-clip” is an option common in the industry and was evaluated for this purpose. However it can require careful alignment of the two mating clips when installing as well as an added expense to purchase the hardware. It needs to be attached to the back of the panel with screws, and so sculpted panels that vary in thickness present the possibility that these screws could penetrate through the face of the paneling. Using thicker panels were considered but rejected due to some of the disadvantages of that option include higher costs for materials and shipping, greater weight to support on the wall and greater difficulty in handling through the manufacturing and installation processes. A related technique is the use of “French cleats”, typically two wood strips with mating beveled edges. An advantage that this has over the use of Z-clips is that it can be glued to the back of the panel eliminating the screw-through disadvantage. Unfortunately, additional material and labor to produce it are required. Still another disadvantage with both of these options, Z-clips and “French cleats” is that the panel must be spaced off of the surface of the wall by their inherent thickness, and therefore require deeper trim elements at exposed panel edges in order to hide their use.

These currently known indirect application methods and devices suffer from several unacceptable disadvantages for these presented problems and call for creating a new solution. Additional hardware or mounting blocking must be purchased or manufactured. Too much time is spent laying out the installation. The entire assembly extends too far from the wall requiring large edge trim elements.

How to join and trim custom wood panels pose additional challenges. Trim around the perimeter of the panels was explored in many ways. Some currently known examples include a lock miter outside corner, a splined miter outside corner, a solid wood outside corner, a solid wood reveal outside corner, a solid wood reveal inside corner, and a cut-to-fit inside corner. Additional joint and plant assembled joinery issues arise from joinery standards in the absence of specifications. Tightness of plant assembled joints between laminated components must address maximum gap and flushness variation factors. AWI/AWMAC 8th edition quality standards pages 250, 264, 267 (2003).

Prefabricated aluminum extrusions were considered at length. Many of these come with concealed mounting strips, which satisfy the hidden fastener requirement. The availability of multiple shapes of extrusion fit in well with the variety of panel patterns and finishes giving lots of design options. The options explored for installation of these extrusions were varied as well. One method was to attach the trim to the panel prior to mounting. Another method involved attaching the trim to the wall first creating a frame into which the paneling would be hung. Another method would be to hang the paneling first and then mount the trim to the wall around the paneling. While these extrusions were attractive and available in multiple finishes there was a desire to match the panel's finish exactly and to be able to create custom profiles for the trim. This concept led to experimenting with painted wood for the trim elements.

Very early on the use of an off-the-shelf blind fastener such as a “Klick” fastener manufactured by Friedrich Knapp Gmbh in Austria having U.S. Pat. No. 6,186,698 was experimented with as a means of blind fastening the trim. The dovetail-shaped groove into which this fastener clips is easy to machine into the mating components and the relationship between panel and trim is consistently controlled by this pre-machined relationship. Combining this method of trim attachment with the rabbeted edge of the panel for screw attachment proved to be a harmonious solution to both issues.

Envisioning this treatment around the perimeter of each panel raised an issue of how to treat the joint between adjacent panels. Initially several versions of an intermediate trim element were explored. Again, this trim could be attached using the Klick fastener, thus hiding the attachment screws between panels. The need to allow the panels to expand and contract at this joint complicated this concept. The trim could not be allowed to attach to both of the adjacent panels without allowing movement. This led to experiments involving the machining of a slot very close to the panel's edge that could deform and absorb the expansion of the adjacent panel. Contraction of adjacent panels would simply pull them away from each other, the gap being covered by the intermediate trim element. An inherent advantage to this idea is that the panels would be installed tight to each other without the need for the installer to set the expansion gap. Several iterations of this expansion-absorbing slot were worked out. It was during this process that the idea was put forward of using the slot for the Klick fastener to also serve as the expansion-absorbing slot.

Also at this time the idea of one panel overlaying it's neighbor came into play. If the first panel could be screwed on, then a portion of the second panel slipped beneath the first one's edge, then there would be no need for screws in that edge of the second panel. This was the genesis of the “projection & recess” concept.

Further experimentation with this concept led to the alternating use of projection s and recesses to mutually engage both adjacent panels. This type of symmetry meant that the paneling could be installed the same way starting from either the left or right end of a run of paneling. This affords flexibility to the installer, which he might not otherwise have. This also allowed the panel to be universal in fit when rotated 180 degrees.

Assuming the sculptural pattern on the panel's face was similarly symmetrical, this meant that there need not be a defined top or bottom to each panel.

Next to be refined was the shape of the serpentine edge of the recesses milled into the back of the panel. A bulge was introduced to bear against the web formed by the expansion relief slot of the adjacent panel. The bulge serves to index the panels' relationship when installed. When a panel needs to expand, this bulge deforms the web allowing the panel to expand without buckling.

This concept of interlaced projection s and recesses eliminated the need for the intermediate trim to cover the joint. This has the advantage of allowing the pattern on the faces of adjacent panels to flow across the joint uninterrupted. The edge design in its final form can be machined on all edges if the paneling needs to be multiple courses tall. Otherwise it can be machined on only the vertical edges if that suits the application best. The projection s serve double duty as a screw-mounting protrusion and as a surface to mount perimeter trim using the Klick fasteners. Perimeter edges are machined no differently than meeting edges.

DESCRIPTION OF THE DRAWINGS

This brief description of several views of the drawings, and the detailed description of the invention refers to different views for specifying the figure numbers and reference numerals to the different parts.

FIG. 1 is a front elevational view of a preferred embodiment of the invention as it is used to operatively connect panels together into a substantially fixed relation structure;

FIG. 2 is a rear elevational view of the panel in FIG. 1;

FIG. 3 is a front elevational view of a panel wall under construction with two panels shown mounted on 2×4″ studs and a third panel being moved into position to be secured to the wall.

FIG. 4 is a horizontal section of a portion of the projection of the panel taken along a line 4-4 FIG. 3;

FIG. 5 is a horizontal section of the recess of the panel taken along a line 5-5 of FIG. 3;

FIG. 6 is a horizontal section of the projection and the recess areas of two panels being assembled taken along line 6-6 of FIG. 3;

FIG. 7 is a horizontal section of two panels assembled and mounted to a 2×4″ stud taken along line 7-7 of FIG. 3;

FIG. 8 is a rear elevational view of two mounted panels with a 2×4″ stud in phantom and showing various mounting details including the serpentine edge expansion and the expansion relief aperture in a relaxed position;

FIG. 8 a is the same as FIG. 8 but in a compressed position showing how the invention accommodates dimensional changes in adjacent wood panels from moisture and temperature fluctuations by allowing for expansion both with the elimination of the gap in the serpentine edge expansion area and with the compression of the expansion relief aperture adjacent to the expansion bulge in the recess of the adjacent panel;

FIG. 9 is a perspective view of a preferred embodiment of the invention showing the panel front face of two adjacent panels each having a fastening element on another top side in addition to the other sides of a panel designed for multiple course installation;

FIG. 10 is a similar perspective view of a preferred embodiment of the invention but showing the panel back face of two adjacent panels each having a fastening element on another top side in addition to the other sides of a panel designed for multiple course installation;

FIG. 11 is a perspective view of another preferred embodiment of the invention showing a fastening element mounting for installing perimeter trim onto to a panel edge;

FIG. 12 is a cross-section taken along line 12-12 of FIG. 11 to reveal details with the fastening element installation onto a panel edge with perimeter trim.

DETAILED DESCRIPTION OF THE INVENTION

This disclosure describes the invention and the manner and process of making and using it to enable any person skilled in the pertinent or most nearly connected technological area of the invention to make and use it. The specific physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention as defined by the claims.

A preferred embodiment the present invention is illustrated by way of example in FIGS. 1 through 12. With specific reference to FIGS. 1 through 3, a fastening element 20 comprises a reveal edge 24 and a serpentine edge 26.

FIG. 1 is a front view of the fastening element 20 on a panel 66 as it is used to operatively connect panels together into a structure. FIG. 2 depicts a rear view of the panel 66 in FIG. 1.

An example of a combination of at least two panels 66 in a conventional environment surrounding or associated with a preferred embodiment of the invention is the construction of a wall structure with panels 66 secured to 2×4″ studs 64. FIG. 3 shows a front view of a panel wall under construction with two panels 66 shown mounted on 2×4″ studs 64 and a third panel 66 being moved into position to be secured against the wall.

Reveal edge 24 has a planar shape and is located on the edge of the panel front face 30 of the panel 66 as best seen in FIGS. 4-7. Two adjacent, properly installed wood panels 66 each have a reveal edge 24 close to but not touching each other forming a gap called a reveal expansion 56 as depicted in FIG. 7.

The serpentine edge 26 has a S shape located on the edge of the panel back face 32 of the panel 66. Overall, in FIG. 2 the serpentine edge 26 is shown to extend the entire length of opposing sides of panel 66. Portions of the serpentine edge 26 are shown in FIGS. 4-7, but is best seen in the enlarged view of FIGS. 8 and 8 a.

The serpentine edge 26 includes a projection 40. FIG. 4 shows a portion of the projection 40 of the fastening element 20 on the panel 66. The projection 40 extends from the fastening element 20 in a generally outwardly direction relative to the fastening element 20.

The projection 40 defines an aperture, such as an expansion relief aperture 42. The aperture 42 is disposed away from the serpentine edge of the projection as illustrated in the enlarged view of FIGS. 8 and 8 a. The aperture 42 extends in a generally parallel direction relative to the serpentine edge 26 of the projection 40. Also, the aperture is configured for receiving a trim fastener 62 that provides a hidden connection from the projection 40 to trim, such as perimeter trim 60. As example, one such trim fastener 62, suitable for use in a preferred embodiment of the present invention, is disposed in U.S. Pat. No. 6,186,698 which is incorporated herein by reference thereto. “Klick” fastener is manufactured by Friedrich Knapp Gmbh in Austria.

In addition, the serpentine edge 26 includes a recess 50. FIG. 5 is a horizontal section of the recess of the panel 66. The fastening element 20 defines the recess 50. The recess 50 extends from the fastening element 20 in a generally inwardly direction relative to the fastening element 20 and is configured for receiving a second projection 40 from a second fastening element 20. The projection 40 and the recess 50 are disposed adjacent to each other on the same serpentine edge 26 so that adjacent panels 66 can be operatively connected to each other in a structure.

Furthermore, the fastening element 20 defines a bulge such as an expansion bulge 52. As shown in FIGS. 8 and 8 a, the expansion bulge 52 is disposed upon the serpentine edge 26 of the recess 50, and extends in a generally outwardly direction relative to the fastening element 20. The expansion bulge 52 is configured for transferring an expansion force from the fastening element 20 to aperture 42 of the projection 40 of an adjacent panel 66.

FIG. 6 illustrates a horizontal section of the projection 40 and the recess 50 areas of two panels 66 being assembled. FIG. 7 is a horizontal section of two panels 66 assembled and mounted to 2×4″ studs 64. p FIG. 8 shows a rear view of two mounted panels 66 with a 2×4″ stud 64 in phantom and showing various mounting details including the serpentine edge expansion 58 and the expansion relief aperture 42 in a relaxed position. FIG. 8 a depicts the same as FIG. 8 but in a compressed position showing how the invention accommodates dimensional changes in adjacent wood panels 66 from moisture and temperature fluctuations by allowing for expansion both with the elimination of the gap of serpentine edge expansion 58 and with the compression of expansion relief aperture 42 adjacent to expansion bulge 52 in the recess 50 of the adjacent panel 66.

FIG. 9 shows the panel front face 30 of two adjacent panels 66 each having a fastening element 20 on a top side in addition to the other left and right sides of a panel 66 for installing a multiple course structure.

FIG. 10 illustrates the panel back face 32 of the two adjacent panels 66 shown in FIG. 9 with each also having a fastening element 20 on top side in addition to the other opposing sides of a panel 66 designed for multiple course installation.

In FIG. 11, a fastening element 20 mounting is depicted for installing perimeter trim 60 onto to a panel 66 edge. FIG. 12 reveals details of the fastening element 20 as used to install onto the panel 66 edge some perimeter trim 60.

In use on a panel 66 to panel 66 construction, a first panel 66 having a fastening element 20 on at least one side may be secured to 2×4 studs 64 of a wall with common fasteners 68, such as screws driven through a countersunk screw hole 48 on the projections 40. As shown in FIGS. 3, 9, and 10, a second panel 66 having a fastening element 20 on at least one side, is placed into the fasting element 20 of the adjacent first panel 66. The projections 40 on right side of the second panel 66 (are inserted into the recesses 50 on the left side of the adjacent first panel 66. Then the projections 40 on the opposing left side of the second panel 66 from the adjacent first panel 66 may be secured to 2×4 studs 64 of the wall. The need to similarly secure the right side of the second panel 66 with fasteners 68 into the stud 64 is eliminated because the recesses 50 on the left side of the first panel 66 supports and secures the projections 40 on the right side of the second panel 66.

In use on a panel 66 to trim 60 construction, the fastening element 20 is included on each side of each panel 66 that will receive the perimeter trim 60 as shown in FIGS. 9, 10, and 11. A trim fastener 62, such as a Klick fastener is depicted in FIGS. 11 and 12. One portion of the trim fastener 62 is inserted into the expansion relief aperture 42 of a projection 40 located on the exposed perimeter of the panel 66 to be framed. The trim, such as perimeter trim 60 is shown in FIGS. 11 and 12 to be attached to the exposed other portion of the trim fastener 62 which is inserted into the expansion relief aperture 42 of a projection 40 thereby securing and hiding the formerly the exposed perimeter of the panel 66 with trim 60.

While the fastening system for panels and trim of the present invention has been disclosed in the drawings in a particular way with a given number and shape of left and right projections 40 and recesses 50 on a panel 66, it should be appreciated that the fastening system can be used in other environments with different variations within the same invention. For example, projections 40 and recesses 50 could be spaced further apart such as with 4 left and 3 right projections on opposing panel 66 sides. Other variations in size and shape are understood to be included in the invention such as wider projections 40 and rectangular projections 40.

The present invention provides an improved fastening system for panels and trim to guide and to operatively connect panels 66 together and to connect a panel 66 with trim 60. The same fastening element 20 provides multiple use capabilities for reducing manufacturing and labor costs for eliminating a current need to manufacture, purchase, install and adjust additional specialized panel joining hardware or mounting blocks, and for reducing the time spent laying out the installation.

When hanging a panel 66 with another adjacent panel 66, the fastening element 20 guides and connects adjacent panel front faces 30 into a flush horizontal alignment with each other for eliminating the need to purchase, and the labor cost of installing a separate additional element such as a spline, wood biscuit, dowel, or other mechanical alignment hardware. Also, the fastening element 20 vertically aligns adjacent multiple course panels 66 with each other for reducing dependence on the variable skill of an installer and for eliminating the need of additional mechanical gauges and alignment tools along with the skill to use them.

The present invention provides a way to attach panels 66 closer to and laying flatter against a wall presenting a diminished profile for reducing the size of required finishing trim 60. Also the invention provides an attachment method and means that can be augmented with adhesives for reducing the number of required fasteners 68 and for providing temporary clamping.

Even more importantly, the fastening element 20 securely affixes panels 66 with fasteners 68 such as screws that are hidden by adjacent panels 66 for eliminating exposed fasteners along with the need to conceal fasteners 68 with putty or mechanical covers. See FIGS. 4-7.

The fastening element 20 further provides a means of accommodating dimensional changes in fixedly secured adjacent wood panels 66 from moisture and temperature fluctuations for reducing the possibility of installing the wood panels 66 with insufficient or omitted allowance for expansion and buckling that may result in costly panel 66 damage.

As shown in FIG. 8, expansion bulge 52 of recess 50 on a first panel 66 contacts the web 46 of projection 40 of another panel 66 to create the serpentine edge expansion 58 and consequently the reveal expansion 56 as seen in FIG. 7. Together they gauge reveal spacing between adjacent panels 66 for eliminating the need for separate spacing shims or for depending on the variable skills of different installers.

Finally, the present invention provides an improved fastening system to connect a panel 66 to trim 60 with the fastening element 20. Perimeter trim 60 may be applied with a hidden trim fastener 62 facilitated by the expansion relief aperture 42 onto many structurally different panel 66 designs for eliminating the need to affix trim 60 by additional modification of an exposed panel 66 edge.

The invention described above may be embodied in other forms without departing from the spirit or essential characteristics thereof. The embodiments disclosed in this application are to be considered in all respects as illustrative and not restrictive. The scope of the invention is indicated by the appended claims rather than by the foregoing description and all changes which come within the meaning and range of equivalency of the claims are intended to be embraced therein. 

1. A fastening element comprising: a reveal edge; and a serpentine edge, with the serpentine edge including: a projection, with the projection extending from the fastening element in a generally outwardly direction relative to the fastening element, with the fastening element defining a recess, and with the projection and the recess disposed adjacent to each other on the same serpentine edge.
 2. The fastening element of claim 1, wherein the projection defines an aperture, with the aperture disposed away from the serpentine edge of the projection, with the aperture extending in a generally parallel direction relative to the serpentine edge of the projection, with the aperture configured for receiving a trim fastener, and with the trim fastener configured for connecting a trim.
 3. The fastening element of claim 2, wherein the fastening element defines an expansion bulge, with the bulge disposed upon the serpentine edge of the recess, with the bulge extending in a generally outwardly direction relative to the fastening element, with the bulge configured for transferring an expansion force from the fastening element to aperture of the projection of an adjacent panel.
 4. The fastening element of claim 1, wherein the projection defines an aperture, with the aperture extending in a generally parallel direction relative to the serpentine edge of the projection, with the aperture disposed at a predetermined distance away from the serpentine edge of the projection, and with the aperture configured for dissipating an expansion force from an adjacent panel.
 5. The fastening element of claim 4, wherein the fastening element defines an expansion bulge, with the bulge disposed upon the serpentine edge of the recess, with the bulge extending in a generally outwardly direction relative to the fastening element, and with the bulge configured for transferring an expansion force from the fastening element to aperture of the projection of an adjacent panel.
 6. The combination of at least two panels and a fastening element, the fastening element comprising: a reveal edge; and a serpentine edge, with the serpentine edge including: a projection, with the projection extending from the fastening element in a generally outwardly direction relative to the fastening element, with the fastening element defining a recess for receiving a second projection from a second fastening element, with the recess extending from the fastening element in a generally inwardly direction relative to the fastening element, with the recess configured for receiving a second projection from a second fastening element, and with the projection and the recess disposed adjacent to each other on the same serpentine edge, whereby adjacent panels can be operatively connected to each other in a structure.
 7. The combination of at least a panel, a trim fastener, a trim and a fastening element, the fastening element comprising: a reveal edge; and a serpentine edge, with the serpentine edge including: a projection, with the projection extending from the fastening element in a generally outwardly direction relative to the fastening element, with the projection defining an aperture, with the aperture disposed away from the serpentine edge of the projection, with the aperture extending in a generally parallel direction relative to the serpentine edge of the projection, with the aperture configured for receiving a trim fastener, and with the trim fastener configured for connecting a trim, whereby the panel can be operatively connected to the trim. 